Manual Lippke4500

Package Test System 4500
Operators Manual
Revision C1
7500 Boone Avenue North

Minneapolis, Minnesota 55428 USA
Telephone 763-493-6370 FAX 763-493-6358
Technical Service 763-493-7250
Customer Service 763-493-7265
E-mail Address: instrument_support_services@mocon.com
http://www.mocon.com
Part Number 143-153

Lippke is a trademark of Mocon, Inc.
Lippke 4500 Table of Contents
Table of Contents
Chapter 1 : Safety Information .......................................................................................................................................1-1
Safety Instructions ....................................................................................................................................................1-2
Assembly, installation and commissioning...............................................................................................................1-2
Use for the intended purpose and application..........................................................................................................1-2
Who is allowed to operate the system?....................................................................................................................1-2
Reconstructions and modifications...........................................................................................................................1-3
Limits of the obligation to instructions and training ..................................................................................................1-3
How to switch on and off the system safely .............................................................................................................1-4
Chapter 2 : Introduction .................................................................................................................................................2-1

System Overview......................................................................................................................................................2-1
Test Capabilities .......................................................................................................................................................2-1
Burst Test .................................................................................................................................................................2-2
Pressure Loss Test...................................................................................................................................................2-3
Creep Test................................................................................................................................................................2-4
Creep to Fail Test .....................................................................................................................................................2-5
Combined Testing ....................................................................................................................................................2-6
Chapter 3 : System Controls & Components.................................................................................................................3-1

The Front Panel........................................................................................................................................................3-1
Back Panel Connections ..........................................................................................................................................3-2
Package Fixtures and Accessories ..........................................................................................................................3-3
The Closed Package Fixture .............................................................................................................................3-3
The needles .......................................................................................................................................................3-4
The Septa ..........................................................................................................................................................3-5
The Filter ............................................................................................................................................................3-6
The Tube Adapter ..............................................................................................................................................3-6
The ASTM Compliant Restraining Plate ............................................................................................................3-7
The Simple Tube Adapter ..................................................................................................................................3-7
The Automatic Package Clamp PPC 300 II.......................................................................................................3-8
The IV bag adapter ............................................................................................................................................3-8
Chapter 4 : Installation and Set Up................................................................................................................................4-1

Unpacking.................................................................................................................................................................4-1
Electrical Requirements ...........................................................................................................................................4-1
Environmental Requirements ...................................................................................................................................4-1
Compressed Air Supply Requirements ....................................................................................................................4-2
System Set Up..........................................................................................................................................................4-2
Chapter 5 : Menu Structure............................................................................................................................................5-1
Chapter 6 : Maintenance................................................................................................................................................6-1
Chapter 7 : Troubleshooting ..........................................................................................................................................7-1

Problems during Measurement ................................................................................................................................7-2
Chapter 8 : Technical Data ............................................................................................................................................8-1
Chapter 9 : Spare parts..................................................................................................................................................9-1
Chapter 10 : Warranty and Service Policies ................................................................................................................10-1
Chapter 11 : Leak Rate and Hole Size Calculation .....................................................................................................11-1

Leak Rate Calculation Using ASTM F2095............................................................................................................11-1
Hole Size Calculation using Hagen-Poiseullies Law .............................................................................................11-2
MOCON, Inc. Revision C iii

Table of Contents Lippke 4500
Figures
Figure 2-1: The Burst Test ........................................................................................................................... 2-2
Figure 2-2: The Pressure Loss test.............................................................................................................. 2-3
Figure 2-3: The Creep Test.......................................................................................................................... 2-4
Figure 2-4: The Creep to Fail Test ............................................................................................................... 2-5
Figure 3-1: Lippke 4500 Front Panel ........................................................................................................... 3-1
Figure 3-2: The Back of the Lippke 4500 ..................................................................................................... 3-2
Figure 3-3: Closed Package Fixture............................................................................................................. 3-3
Figure 3-4: Needle Type 1B ......................................................................................................................... 3-4
Figure 3-7: Septa black 3 mm ...................................................................................................................... 3-5
Figure 3-8: Septa grey 1 mm ....................................................................................................................... 3-5
Figure 3-9: Construction of filter................................................................................................................... 3-6
Figure 3-10: Tube Adapter with tube ........................................................................................................... 3-6
Figure 3-11: ASTM Restraining Plate .......................................................................................................... 3-7
Figure 3-12: Simple tube adapter ................................................................................................................ 3-7
Figure 3-13: PPC 300 II ............................................................................................................................... 3-8
Figure 3-14: Intravenous Bag Adapter ......................................................................................................... 3-8
Tables
Table 3-1: Front Panel Controls ................................................................................................................... 3-1
Table 3-2: Electrical Connections ................................................................................................................ 3-2
Table 3-3: Pneumatic Connections .............................................................................................................. 3-2
Table 7-1: System Errors ............................................................................................................................. 7-1
Table 7-2: Interface Errors ........................................................................................................................... 7-1
Table 8-1: Dimensions and Weights ............................................................................................................ 8-1
Table 9-1: Spare parts ................................................................................................................................. 9-1
Table 11-1: Parameters Hagen-Poiseuille ................................................................................................. 11-2
MOCON, Inc. Revision C iv

Lippke 4500 Safety Information
Chapter 1: Safety Information
This operators manual must be read, understood and observed before commissioning the system.
If one of the following safety instructions is not or only partially observed, MOCON Inc. or Paul
Lippke Handels-GmbH can assume no responsibility for any consequential damages, defects or the
reliability of the test system.
We proceed on the assumption that the operator will use this test system carefully and sensibly.
You must not continue system operation if any system malfunctions occur.
The test system must not be modified with regard to its construction and design without prior
consultation of the manufacturer.
Please make sure that the test system is connected only to the mains power supply specified on the
nameplate.
Please make sure that the compressed air supply does not exceed the maximum supply pressure
specification.
Please provide sufficient air circulation and install the test system with a sufficient distance from
other objects.
Never clean the test system with any liquids if it is connected to the mains socket-outlet.
Disconnect the test system from the mains line and remove the compressed air supply before
opening the front or rear panel.
Maintenance should be performed by qualified personnel. If you have any questions, feel free to
contact MOCONs technical service department in the USA. We want you to receive the best in
product support services.
The following symbols are used in order to obtain more clarity:
Caution: Please observe all instructions.
Important note, may lead to malfunction or damage of test system if not observed
Note, which is helpful in operating and using the test system.
MOCON, Inc. Revision C 1-1

Safety Information Lippke 4500
Safety Instructions
The Lippke Package Test System 4500 was built according to the state of the art and all valid regulations
and engineering rules. However, this system can be dangerous for persons and objects if the following
regulations are not observed:
- The system must be used only for the intended purpose and application
- The system must only be operated by qualified personnel
- It is not allowed to modify, reconstruct or remodel the system improperly
- Safety notices must be observed
For this reason, any person dealing with the operation, maintenance and repair of the vacuum-leak test
system has to read and observe the safety regulations.
It is self-evident that the following regulations apply as well:
- all relevant rules for prevention of accidents
- generally accepted safety regulations
- regulations specific to countries and states
Assembly, installation and commissioning

Only authorised persons are allowed to install and commission the Lippke 4500 Package Test System.
Please make sure that this system is only operated with the mains voltage indicated on the nameplate.
Use for the intended purpose and application

This system is only to be used for the processes mentioned under "Specifications".
Any other use or application is considered as non-compliant and can result in dangers to persons or device
damage.
It is not permitted to continue operation if malfunctions or trouble occur on the system.
Who is allowed to operate the system?

Only qualified, instructed, trained and authorized persons are allowed to operate the system.
Responsibilities and competences must be observed during operation. Special knowledge is required for
maintenance and repair and these works are to be carried out only by qualified skilled personnel.

Reconstructions and modifications
For safety reasons, no unauthorized modifications on the system are permitted. Original parts and
accessories were designed specifically for this system. We emphasize that parts not delivered by us and
optional extras are not approved and released by us. Mounting and/or using such products can also affect
active and/or passive safety. The manufacturer cannot be held responsible for damages caused by using
other parts or options other than the original parts or options.
Limits of the obligation to instructions and training

By preparing this user manual, we made every effort to provide the customer with all instructions necessary
for the proper and efficient use of the system.
However, there are limits to the manufacturer's obligation to training and instructions.
Any person using machines or other technical equipment is obliged to inform himself about how he can use
this machine or equipment safely and according to applicable regulations.
Therefore, the user has certain obligations of application. In other words, we took the user's care and
attention for granted when we prepared this operating manual.
From this, it follows that we are not obliged to point out what is "general knowledge from experience".
This device built by the PAUL LIPPKE HANDELS-GMBH was designed according to the state of the art and
all valid and applicable regulations and according to standard engineering rules.

How to switch on and off the system safely
Only employees who were instructed and trained on the system itself can switch on and off the system
safely. Moreover, they must have been instructed properly with regard to:
- functions
- dangers
- safety measures
in order to make sure that they switch on and off this system safely.
Only switch on - if no persons will be endangered
In case of interlinked plants - observe warning signals
- exclude mutual endangering
In case of malfunctions - switch off the system
- inform foreman (superiors)
Before maintenance - set up and observe safety measures
- switch off power supply
- secure against unauthorized restart
- observe instructions in user manual
First think - then take action!

Lippke 4500 Introduction
Chapter 2: Introduction
System Overview
The Lippke 4500 is an integrated package test system that measures the seal strength and integrity of
flexible, rigid or semi-rigid packages. The seal strength and integrity of the package is measured by inflating
the package using compressed air.
The system consists of a console and one or more package fixtures. The entry, selection and management
of all test parameters can be easily and quickly accomplished using the simple controls on the instrument
front panel. Multiple test configurations can easily be created and recalled using alphanumeric names.
A package fixture is used to connect the pneumatic controls and pressure sensors in the system console to
the package. Fixtures are available for testing the most commonly used types of packages. There are a
variety of fixture types are available for closed packages, open packages, screw top tubes and IV bags.
The system is shipped with a Closed Package fixture. The closed package fixture is used for testing
packages that are sealed on all sides. The closed package fixture consists of an adjustable stand and a
needle head used to pierce the package. Several types of needles and septa are available to meet most of
the common testing requirements. To perform restrained tests on closed packages, compliant with ASTM
F2054, an optional Restraining Plate fixture is available.
To test packages, bags or pouches that are open on one side an Open Package fixture is required. The
optional PPC 300 II Automatic Package Clamp is available for performing bust tests on most types of open
packages. The PPC 300 comes equipped with an integral restraining plate system.
Test Capabilities
The 4500 Package Test System can perform a variety of seal strength and package integrity tests. Three
types of Seal Strength and two Integrity tests can be performed individually or in combination.
The following Standard tests can be performed:
Burst/Seal Strength Test

Pressure Loss/Leak Test
When the Hole Size option has been purchased, a Leak Rate (ASTM F2095) and theoretical Hole Size will
be reported for each Pressure Loss/Leak Test.
When the Multi-Test option has been purchased, the following tests can be performed:
Creep Test
Creep-to-Fail Test
Combined Creep & Burst
Combined Creep & Leak
Combined Creep & Leak & Burst
For more detailed information on each of these tests see the appropriate sections later in this chapter.

Introduction Lippke 4500
Burst Test
Also called Seal Strength Test. The package is connected to the instrument via a PPC or needle (or the
ASTM Compliant Restraining Plate) and the package seal strength is determined by increasing the pressure
in the package until it bursts. If the preset maximum pressure is reached, the test will stop. The Burst Test is
compliant with ASTM F2054.
Caution: In a burst test, the package will typically burst. This may lead to
considerable noise. Suitable hearing protection should be worn.
Note: When testing filled packages, precautions may be necessary to insure that
the product does not contaminate the operator or the system. Depending on
the package contents, the use of safety glasses may be advisable. A
protective hood placed over the package may offer additional protection.
The test is divided in 2 phases.
Phase 1: Increasing the package to the pre-filling limit.

Phase 2: The pressure in the package is increased at the preset rate until the package bursts
or the maximum specified pressure is reached.
P
Upper Limit
Burst
Lower Limit
Prefilling
Press re
t
Figure 2-1: The Burst Test
The results are:
The Burst Pressure if the package bursts

The Time of the package burst
PASS if the package bursts within the preset burst limits
FAIL if the package bursts outside the preset burst limits
Caution: If the package did not burst, it is still under pressure! Remove the
package carefully; a sudden pressure drop will occur when it is removed.

Pressure Loss Test

This test method is used to evaluate the integrity of a package. The package is connected to the instrument
with the needle head and the pressure inside the package is set to 30-50% of the burst pressure. The test
pressure and the pressure lost during the test can be used as a measure of package integrity.
When the Hole Size option has been purchased, this information can be used to calculate a Leak Rate and
aggregate Hole Size. The Pressure Loss and Leak Rate calculations are compliant to ASTM F2095.
Caution: It is possible that the package will burst in this test mode. Please note
that the pressure may not drop to a low level immediately after the test.
The test is divided into in 3 Phases
Phase 1: The internal pressure is increased to the test level

Phase 2: Compensation or settling time The internal pressure in the package is maintained at
the specified level. This time is used to reduce thermal effects.
Phase 3: Test Time The pressure loss during the test phase is measured
Test pressure
P
Pressure loss
Pass/Fail Limit
Compensation
t
Test Time
Figure 2-2: The Pressure Loss test
The results are:
The pressure decrease during the test time

PASS or FAIL depending on the preset limit
The Leak Rate according to ASTM F2095 (only available if the option was purchased)
The theoretical Hole Size of the package (only available if the option was purchased)

Creep Test
The Creep Test is used to evaluate the seals on a package. It is a Pass/Fail test. A Creep Test increases
the pressure in the package to a
specified value (approximately 80% of the burst pressure) and maintains it for a specified time period. The
package passes if it does not burst during the test. The Creep Test is compliant with ASTM F1140.
Caution: This test may cause the package to burst. Please note that the
pressure may not drop to a low level immediately after the test.
the product does not contaminate the operator or the system. Depending
on the package contents, the use of safety glasses may be advisable. A
The test is performed in 2 phases:
Phase 1: The pressure in the package is increased to the test level.

Phase 2: The pressure in the package is maintained at the test pressure for the specified time.
The test result is Pass or Fail
Test pressure
P
t
Test Time
Figure 2-3: The Creep Test

Creep to Fail Test

This test is similar to the Creep Test, but a test pressure between 95%-100% of the burst pressure is used.
The test pressure should be high enough to cause a slow but progressive failure during the specified test
time. The Creep Test to Fail test is compliant with ASTM F1140.
Caution: This test may cause the package to burst. Please note that the pressure
may not drop to a low level immediately after the test.
the product does not contaminate the operator or the system. Depending on
the package contents, the use of safety glasses may be advisable. A
The test is performed in the same way as the creep test. In addition to Pass or Fail the test result contains
the Time to Failure or a NO BURST if the package did not burst.
Test pressure
P
fail pass fail
Lower limit
Upper limit
t
Maximum test time
Figure 2-4: The Creep to Fail Test

Combined Testing
When the Multi-Test option has been purchased, the Creep, Leak and Burst tests (described previously)
can be combined in various ways and performed as a single test. The results of each individual test will be
reported at the end of the test sequence. Combined testing can simplify operator setup and reduce the
number test samples required.
The Combined Testing Option allows the following combined tests to be performed.
Creep & Burst
Creep & Leak
Creep & Leak & Burst
Each test in the sequence is performed as previously described in this chapter.

Lippke 4500 System Overview
Chapter 3: System Controls & Components

The Front Panel
On the front of the Package Test System 4500, there are three indicators. The functions of these indicators
is explained below:
Figure 3-1: Lippke 4500 Front Panel
Control Description
Power This LED is illuminated when the instrument is turned on.
RxD This LED is illuminated when the instrument is receiving data from the computer.
TxD This LED is illuminated when the instrument is transmitting data to the computer.
Table 3-1: Front Panel Controls

System Overview Lippke 4500
Back Panel Connections

The following figures and tables illustrate and describe the connections on the back panel of the Lippke
4500 system console.
Figure 3-2: The Back of the Lippke 4500
Connector Description
Power Input The power input module contains the connector for the power cord, the fuse
Module holder and the Power ON/OFF switch
PC / Printer: The PC/Printer port is a RS-232 port for connection to a printer or computer.
The Accessory Port is used to connect accessories, such as a foot switch,
Accessory Port:
to the instrument console.
Table 3-2: Electrical Connections
Connector Description
The compressed air supply to the instrument console is connected to this port.
Air Supply
The supply pressure must not exceed 8 Bar (116 psig).
Feed The Feed line to the Package Fixture is connected to this port.
Sense The Sense line from the package fixture is connected to this port.
The Clamp output is used to operate optional devices that are not available for
Clamp
the Lippke 4500 system you have purchased.
Table 3-3: Pneumatic Connections

Package Fixtures and Accessories

This section describes the various package fixtures and accessories that are available for use with the
Lippke 4500 test system.
The Closed Package Fixture
To test fully sealed (closed) rigid and semi rigid packages a Closed Package fixture is used. The system is
shipped with a closed package fixture. The fixture consists of an adjustable stand and a Needle Head. A
variety of needles, septa and filters are available to insure that the suitable connection is made to the
package and the sensor is protected from dust.
Figure 3-3: Closed Package Fixture

The needles
The Needle Head on the closed package fixture contains a removable needle. The needle is used to pierce
the package so compressed air can be introduced into the package to perform the test. Two different styles
of needles are available, the mono needles (type 1B and type 2B) and the double needle type 3B.
The Mono needle is suitable for almost all packages. There is less danger of the measuring needle
becoming clogged by the product, since only one needle is used for air supply and pressure measurement.
Piercing the package is easier using needle type 1B (see Figure 3-4) and the use of a needle type 2B (see
Figure 3-5) is recommended for flat packages in order avoid undesired damage to the underside of the
package.
Figure 3-4: Needle Type 1B Figure 3-5: Needle Type 2B
When testing packages, using a Mono Needle, that result in a high flow into the package a significant
pressure differential may occur across the needle. This effect occurs most often with packages made of
materials permeable to air, like sterile paper, Tyvek, etc. The effect may also occur when a high Pressure
Rate setting is used. The Type 3B double needle (see Figure 3-6), uses separate needles for the sense and
feed lines to reduce this effect. An O-ring inside the needle head provides the sealing of both air channels.
Figure 3-6: Needle Type 3B

The Septa
In order to ensure a linear pressure increase in the package and to avoid unnecessarily high consumption
of air it may be necessary to seal the point at which the package is pierced with a septum. The septum also
protects the packaging material from tearing at the puncture point. When testing flat packages, the black
septum is recommended. The thickness of the rubber material (3 mm), allows the flat needle head type 1B
to be used. This needle head provides good sealing without requiring penetration of the needle tip into the
interior of the package.
For small-sized packages that will deform under pressure in the area the package is pierced the grey
septum is recommended. This septum is only 1mm thick and is very flexible.
When performing burst tests it is often not necessary to seal the package with a septum at the puncture
point. If an excessive amount of air escapes during measurement, a septum (with adhesive side to the
needle) can be helpful.
Figure 3-7: Septa black 3 mm Figure 3-8: Septa grey 1 mm
When choosing the puncture point on the package, avoid seams and areas with adhesive. The package
should be pierced in the middle, if possible, in order to ensure that the package will inflate evenly. This is
important, because the needle must lie evenly and tightly on the package. The test head will lift as the
volume of package increases, this will be compensated for by movement of the needle head

The Filter
When testing packages filled with powder or liquid substances, it is highly recommended that the optional
filter be used. If the filter is not used product may contaminate the system causing damage to the
instrument. The filter is installed between the test head and the needle head (see Figure 3-9)
O-Ring O-Ring
Filterfoam nozzle Plexi tube
Meassuring head Filter Needle
Figure 3-9: Construction of filter
Remove the needle and screw the foam filter element with a foam filter to the test head. Then attach the
small filter tube to the filter and then the needle head. For the positions of the individual O-rings please see
Figure 3-9.
The Tube Adapter
The Tube Adapter is used to allow tubes with threaded closures to be tested. Figure 3-10 illustrates how
this type package is attached to the adapter.
Figure 3-10: Tube Adapter with tube

The ASTM Compliant Restraining Plate
Restrained tests compliant with ASTM F2054 can be performed using the Closed Package fixture and the
ASTM Compliant Restraining Plate fixture.
Figure 3-11: ASTM Restraining Plate
The Simple Tube Adapter
This is a simple tube adapter for basic package testing. Caution: the septa are different for the package
holding device
Figure 3-12: Simple tube adapter

The Automatic Package Clamp PPC 300 II
Open packages and pouches can be tested using the PPC 300 II Automatic Package Clamp fixture (see
Figure 3-13). The fixture seals the open side of the package, enabling a burst test to be performed
according to the ASTM F1140 standard. The fixture also contains an integral restraining plate system.
Figure 3-13: PPC 300 II
The IV bag adapter
This is an adapter IV-Bags to be connected to the instrument. The conical shape of the adapter allows for
easy connection to the bag.
Figure 3-14: Intravenous Bag Adapter

Lippke 4500 Installation and Set Up
Chapter 4: Installation and Set Up
Note: Please read the following instructions before beginning the installation
Unpacking
The components for your Lippke 4500 Package Test System may be shipped in one or more cartons
depending on the options that were ordered. To insure you have everything use the Accessories Checklist
as you unpack the components.
If any components are missing or damaged, please call MOCON Technical Services in the USA at (763)
493-7250.
Electrical Requirements
Note: Connection to a electrical power supply different than indicated on the label
can lead to device damage.
The system requires an electrical supply between 110-230 VAC at a frequency of 50/60 Hz (other versions
on request). Please keep in mind that large electrical machines operating close to the system can cause
voltage fluctuations that may produce inaccurate test results or result in damage to the instrument. When in
doubt, connect a line filter ahead of the instrument.
Environmental Requirements
Do not install the system close to heat sources. Protect the system from direct sunlight, formation of dust,
vibrations, liquids and extreme humidity. It is important to meet the following limits:
Condition Limit
Ambient temperature +5 500C (+40 ... 1050F)
Relative humidity 0 ... 90% non-condensing
Table 4-1: Environmental Conditions
Note: Operating the test system outside the above-specified limits may lead to
malfunctions and device damage.
Note: The instrument enclosure complies with protection category IP54

Installation and Set Up Lippke 4500
Compressed Air Supply Requirements
Caution: If specified maximum pressure is exceeded, there is a danger of bursting

of tubing and other components.
Note: Operation to within specification is not guaranteed if the Air Supply pressure
is below the specified minimum input pressure.
The compressed air supply must be dry, clean and free from oil. The input pressure must be between 4 and
8 bar (58 to 116 psi). The input pressure must be at least 1 bar (14.5 psi) above measurement pressure. A
separate pressure regulator is recommended.
We recommend a compressed air quality compliant with DIN ISO 8573 Class 2. If the air quality is not
known, it is recommended be conditioned using of a filter/dryer combination (5 and 0.1) that contains a
regenerative cartridge (e.g. Zander Min-DRY MDK and KT 2016). This will provide precise measuring
results and trouble-free operation of the entire pneumatic system. Air consumption depends on size,
stability and porosity of packages and number of measurements.
System Set Up
All electrical and pneumatic connections are on the back of instrument (see also Figure 3-2).
Follow the steps given below to set up your system:
1. Place the system console and package fixture on a clean flat work surface of sufficient area
for the type of packages to be tested.
2. Connect air pressure supply to the "Air Supply" port.
3. Connect sensor line, the smaller tube, from needle head or PPC to the Sense port.
4. Connect feed line, the larger tube, from needle head or PPC to the Feed port.
5. Connect a power cable to the power inlet connector on the console.
6. Connect the power cable to a suitable power source.
7. If a printer is provided unpack it set it up using the provided instructions.
8. Connect one end of the interface cable to "PC/Printer" port.
9. Connect the other end of the interface cable to a Communication Port on the PC.
Note: Check to insure that all hoses are firmly and tightly connected. Please use
the union nuts provided with the system. This will help insure that all the
connections are safe secure and leak free.

Lippke 4500 Menu Structure
Chapter 5: Menu Structure

The Lippke 4500 Package Test system uses a software application to set up and perform all tests. Details
on how to operate the software can be found in the Help section of the software.
An electronic copy of the Help system document is included on the installation CD and is installed on the
computer when the application is set up.
To start the software application select Lippke Package Test System 4500 from the Start Menu. A User
Name and Password are required to access to the PPG application. Select the appropriate name by
opening the User name list box. The default Password for the Administrator user is admin.

Menu Structure Lippke 4500

Lippke 4500 Maintenance
Chapter 6: Maintenance
The LIPPKE Package Test system 4500 control unit is maintenance-free. This particularly applies to
pneumatic system and electronic control system.
After switching off the system, you can clean its outside surface using a moist cloth if it becomes necessary.
Please always make sure that the holding stand is clean. For this purpose, screw off the needle head from
time to time and check whether the needle is completely clean. The same applies to both openings on the
test head (air supply and pressure sensor opening). Solid residues can be removed carefully by means of a
needle. Liquids should be best blown out. Flushing with water and alcohol is also possible. After that, all
hoses should be blown out thoroughly (apply compressed air to all hose connections) to make sure that no
liquids remain in the holding stand.
Corresponding measures may be taken for the optional filter between test head and needle head. The filter
foam material should be replaced at regular intervals or if it is soiled.
For cleaning the hoses, it is recommended to just blow through them using compressed air.
The O-rings on the needle head guarantee tightness and functioning of the system and must therefore be
replaced periodically. Applying some silicone grease on the O-rings may prolong their service life and
durability and may increase system tightness.
It is recommended to have the system checked by a MOCON technician every year. During such an
inspection all functions (especially control valve and system tightness) as well as the pressure sensors
calibration will be checked. Please contact the MOCON Technical Services group for more information.

Maintenance Lippke 4500

Lippke 4500 Trouble Shooting
Chapter 7: Troubleshooting
The following list of possible error causes and their remedies is not necessarily complete. Should your
system display any errors not mentioned, please do not hesitate to contact us. We will be glad to help you in
any way.
System Errors
Symptom Cause Solution
No display after switching - Loose power cable - Check the connection.
on control unit - Defective fuse - Replace the 1 A fuse.
- Call MOCON
Table 7-1: System Errors
Interface Errors
For clarity, the following error causes are explained for a printer, but they also apply to the PC. Please
observe that all errors are output just once, i.e., the output cannot be repeated.
Symptom Cause Solution

No printer output - Loose interface cable- - Check the connections
printer not switched on - Switch on printer
- Printer is OFF line - Switch printer ON line
Output not in desired lan- - Wrong configuration - Change configuration
guage according to chapter
Configuration, page 26
Strange characters, - Wrong character set - Check settings of printer
(e.g. not displayed (see manual)
Table 7-2: Interface Errors

Troubleshooting Lippke 4500
Problems during Measurement

If the system doesnt build up pressure during a measurement, this may have various causes:
The package is leaking at the needle
The Pressure Rise setting may be too high.
The package is very porous
No compressed air supply
Either the compressed air supply of the system is interrupted or the supply pressure is not high enough if
the package internal pressure is adjusting on a constant level during a running measurement.
After bursting of a package, the system should terminate the measurement automatically. However, if a very
high value was selected for the Auto-Stop Threshold, it is possible that the test will not terminate
automatically. The Auto-Stop Threshold value should be reduced.
The following is a symptom of a clogged needle: the package is not inflated fully even though a pressure
rise is displayed. In this situation, abort the measurement by pressing the STOP key and clean the needle
(see Chapter 8).
If you have noticed that pressure loss is far too high for one package, this may have the following causes:
The Septum is leaky
Poor adhesion of the septum because of dirty package surface
Porous O-Ring

Lippke 4500 Technical Data
Chapter 8: Technical Data

Air pressure supply: 4.0 8.0 bar / 60 - 120 psi
Supply voltage: 100 - 250 V AC
Mains frequency: 50/60 Hz 1 Hz
Environmental temperature: +15 C - +40 C

Environmental RH: 0 % - 90 % non-condensing
Protection Class: IP 54
Pressure units: mbar, mmHg, psi

Test Time: 1 s - 9.999 min
Three Measuring Ranges: 1 0 ... 1000 mbar / 0 ... 14.5 psi

2 0 ... 3000 mbar / 0 ... 43.5 psi
3 0 ... 7000 mbar / 0 ...101.5 psi
Resolution per Measuring Range: 1 0.1 mbar / 0.0015 psi

2 1.0 mbar / 0.015 psi
3 1.0 mbar / 0.015 psi
Accuracy per Measuring Range: 1 0.5 mbar / 0.007 psi or 1 %*

2 2.0 mbar / 0.030 psi or 1 %*
3 5.0 mbar / 0.070 psi or 1 %*
Reproducibility per Measuring Range: 1 0.5 mbar / 0.007 psi or 1 %*

2 2.0 mbar / 0.030 psi or 1 %*
3 5.0 mbar / 0.070 psi or 1 %*
* whichever is greater
Languages: German
English
France
Spanish
Italian
Swedish
Polish
Dimensions and weights

The following table lists dimensions and weights of the system including accessory:
Width / Inch Height / inch Depth / inch Weight / kg

Control unit 13.8 7 13.8 6.5
Holding stand 13 10 15.7 3.6
PPC300 II 20 7.9 18.5 20
ASTM Plate 15.7 14.7 5.1 13.5
Table 8-1: Dimensions and Weights

Technical Data Lippke 4500

Lippke 4500 Spare Parts
Chapter 9: Spare parts

Unit of
Part Number Description Quantity
Measure
035-342 Pneumatic Package Clamp, PPC 300 1 EA
035-347 Needle, Sharp, 1B 1 EA
035-348 Needle, Blunt, 2B 1 EA
035-349 Needle, dual, 3B 1 EA
035-350 Septum, Gray, 4mm 100 EA
035-351 Septum, Black, 4mm 100 EA
035-534 Filter Set 1 EA
050-151 USB to Serial Adapter 1 EA
Table 9-1: Spare parts

Spare Parts Lippke 4500

Lippke 4500 Warranty and Service Policies
Chapter 10: Warranty and Service Policies

Warranty and Service Policies Lippke 4500

mocon
EFFECTIVE DATE: June 28, 2007
Minneapolis, MN 55428 U.S.A.

763-493-6370 Fax 763-493-6358
WARRANTY POLICY
STATEMENT OF LIMITED WARRANTY
MOCON warrants that any part of any MOCON instrument or accessory which proves to be defective in material or workmanship
during the warranty period will be repaired by MOCON certified service personnel only, or at MOCONs option replaced, free of
charge, F.O.B. MOCONs factory. Please consult the MOCON technical services department to determine which warranty statement
applies to your instrument. This warranty applies to the original purchaser only, and is subject to the following terms and conditions:
1. Units or systems with MOCON offered field training, either purchased as an option or included in the purchase price.
One year from date of shipment from MOCONs factory if field training is performed by MOCON personnel or
certified representatives.
Ninety days from date of shipment from MOCONs factory if field training is not purchased.
One year from date of shipment from MOCONs factory if an extended warranty is purchased as an option or
included in the purchase price (not available on all instruments).
2. Units or systems without field training offered by MOCON.
One year from date of shipment from MOCONs factory.
3. Spare parts, repairs and accessories when purchased separately and not a part of a new instrument order.
Ninety days from date of shipment from MOCONs factory.
4. This warranty covers normal use only. It does not cover damage that results from alteration, accident, misuse, abuse,
neglect, or failure to follow assembly, installation, operational, or other MOCON instruction.
5. All warranty repair items are to be shipped at purchasers expense, to and from MOCON.
6. THE FOREGOING SHALL CONSTITUTE THE SOLE AND EXCLUSIVE REMEDY FOR ANY PURCHASE OF
MOCON PRODUCTS, AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED, IMPLIED OR STATUTORY,
WHICH ARE HEREBY DISCLAIMED AND EXCLUDED BY MOCON, INCLUDING WITH LIMITATION, THE IMPLIED
WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND USE AND ALL
OBLIGATIONS AND LIABILITIES ON THE PART OF MOCON FOR DAMAGES ARISING OUT OF OR IN
CONNECTION WITH THE USE OF REPAIR OR PERFORMANCE OF THE PRODUCT. IN NO EVENT SHALL
MOCON BE LIABLE FOR ANY INDIRECT INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES OR FOR ANY
DELAY IN THE PERFORMANCE BY MOCON OF ANY OF ITS OBLIGATIONS UNDER THE FIELD SERVICE
AGREEMENT OR THIS WARRANTY DUE TO CAUSES BEYOND ITS CONTROL.
7. In no event shall MOCON be liable for any damages in excess of the price paid for software including, but not limited
to, direct, consequential (including, without limitation, lost profits), special, exemplary, incidental and indirect damages,
arising out of or in connection with the use, the results or the inability to use the software, and imposed under any
cause of action whatsoever, including contract, warranty, strict liability, or negligence, even if MOCON has been
notified of the possibility of such damages.
MOCON software is provided as is and MOCON makes no warranty as to the software. MOCON DISCLAIMS ALL WARRANTIES,
EXPRESS OR IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, RELATED
TOTHE SOFTWARE, ITS USE OR ANY INABILITY TO USE IT, AND THE RESULTS OF ITS USE.
MOCON IS A REGISTERED TRADEMARK OF MOCON, INC.

Copyright 2001 MOCON, Inc. All rights reserved.
P/N 032-846


mocon
EFFECTIVE: JANUARY 6, 1998

763-493-6370 Fax 763-493-6358
INTERNATIONAL SERVICE POLICY
MOCON offers a complete range of service options to purchasers of MOCON instrumentation and systems.
SERVICE PERFORMED WITHIN THE WARRANTY PERIOD
1. PART REPLACEMENT
If a defective part can be located, a free replacement part can be shipped collect to the customer for installation by in-
house repair personnel. This is the fastest and least expensive way to get the equipment operating again.
2. RETURN UNIT TO MOCON U.S.A.

If replacing the part appears to be beyond the Purchasers normal range of talents, the Customer may elect to ship the
instrument back to the factory in Minneapolis, Minnesota, U.S.A., for repairs. In this case, the Customer is responsible for
round trip freight, insurance, and duties, with MOCON providing all labor and materials free of charge, subject to warranty
restrictions. Our Service Department will keep turnaround time to a minimum.
3. LOCAL SERVICE (IF AVAILABLE)

Another option is to have your local representative travel to your plant to facilitate repairs on equipment. If a special trip to
your location is necessary, you may be required to pay for all time and travel expenses. Once the representative arrives at
your plant, parts (if covered by warranty) are free of charge. Contact your representative for labor rates.
3. U.S.A. SERVICE PERSONNEL

When the malfunction is considered an emergency, MOCON service personnel can be dispatched from the U.S.A. to visit
your facility and to correct the problem you are experiencing. The charges for this service include all out-of-pocket travel
expenses and portal-to-portal travel time. Labor and parts expanded while on your premises are free of charge, subject to
warranty restrictions.
SERVICE PERFORMED AFTER THE WARRANTY PERIOD

4. PART REPLACEMENT
If a defective part can be located, a replacement can be shipped to the Customer for installation by in-house repair
personnel. Charges will include the cost of the parts plus shipping. This is the fastest and least expensive way to get the
equipment operating again.
5. RETURN UNIT TO MOCON U.S.A.

If replacing the part appears to be beyond the capability of in-house personnel, the instrument may be shipped back to the
factory in Minneapolis, Minnesota, U.S.A., for repairs. The customer is responsible for round trip freight, insurance and
duties, and will be billed for parts and labor required to accomplish the repair. If the required parts are in stock, turnaround
time is minimal.
6. LOCAL SERVICE (IF AVAILABLE)

A request may be made for your local representative to visit your facility. If a special trip to your location is required, you
will be billed for time, travel expenses, and parts. If you are unsure of whether you have a local representative, please
contact MOCON and we will direct you to the location nearest you.
7. U.S.A. SERVICE PERSONNEL

When the malfunction is considered an emergency, MOCON service personnel can be dispatched from the U.S.A. to visit
your facility and to correct the problem you are experiencing. The charges for this service include travel expenses incurred,
portal-to-portal travel time at prevailing labor rates, and parts expended.
MOCON is a registered trademark of MOCON, Inc.

P/N 032-847A


mocon
EFFECTIVE DATE: January 6, 2001

763-493-6370 Fax 763-493-6358
Customer Service 763-493-7265 DOMESTIC SERVICE POLICY
MOCON offers a complete range of service options to purchasers of MOCON instrumentation and systems.
SERVICE PERFORMED WITHIN THE WARRANTY PERIOD

1. PART REPLACEMENT
If a defective part can be located, a free replacement part can be shipped F.O.B. MOCON factory to the Customer for
installation by in-house repair personnel. Charges include cost of insurance plus shipping. This is the fastest and least
expensive way to get the equipment operating again.
2. RETURN UNIT TO MOCON

If replacing the part appears to be beyond the capability of the Customers in-house personnel, the Customer may elect to
ship the instrument back to the factory in Minneapolis, Minnesota, for repairs. In this case, the Customer will pay the
charge for round trip freight and insurance, with MOCON providing all labor and materials free of charge subject to
warranty restrictions.
3. SERVICE REPRESENTATIVE VISIT
If malfunction is considered by MOCON to be an emergency, a MOCON service representative will be dispatched from
MOCON to visit the Customers facility to correct the problem. The charges to the purchaser for this service include all out-
of-pocket travel expenses, including meals and lodging and the service technicians portal-to-portal travel time at the
prevailing labor rates. Labor and parts expended while on the Customers premises are free of charge, subject to warranty
restrictions.
SERVICE PERFORMED AFTER WARRANTY PERIOD

In the event that repairs are required after the warranty period, the Purchaser again has several alternatives.
4. PART REPLACEMENT
If the customer can identify a defective part, a replacement can be shipped F.O.B. MOCON factory to the customer for
installation by in-house repair personnel. Charges will include the cost of the parts plus shipping. This is the fastest and the
least expensive way to get the equipment operating again.
5. RETURN UNIT TO MOCON
If replacing the part appears to be beyond the capability of the Customers in-house personnel, the instrument may be
shipped back to the MOCON factory in Minneapolis, Minnesota for repairs. The Customer is responsible for the cost of
round trip freight and insurance, and will be billed for parts and labor required accomplishing the repair.
6. SERVICE REPRESENTATIVE
If malfunction is considered by MOCON to be an emergency, a MOCON service representative will be dispatched from
MOCON to visit the Customers facility to correct the problem. The charges for this service include out-of-pocket travel
expenses including portal-to-portal travel time at prevailing labor rates, parts used, and labor at the prevailing labor rates to
repair the equipment.
GENERAL TERMS AND CONDITIONS

7. Invoices are due NET 30 days (with approved credit) and are billed and payable in U.S. dollars.
8. All parts are shipped F.O.B. MOCON factory Minneapolis, Minnesota; freight and Insurance will be billed separately.
9. MOCON insures all shipments unless advised otherwise.
10. All repairs after the original instrument warranty period are warranted for 90 days on parts and labor, F.O.B. MOCON
factory.
Please refer to the latest version of MOCONs Warranty Policy sheet for warranty information.
MOCON is a registered trademark of MOCON, Inc.

P/N 032-848A

Lippke 4500 Warranty and Service Policies
Chapter 11: Leak Rate and Hole Size Calculation

This chapter explains how a Leak Rate and Hole Size are derived using the data obtained during a
Pressure Loss test. A Leak Rate and Hole Size are only calculated and reported if the Hole Size option
has been purchased. The Hole Size option can only be installed at the factory.
Leak Rate Calculation Using ASTM F2095

To calculate a leak rate (Volume Flow) a Pressure Loss P, Time t and Volume are needed. The
Pressure Loss and Time are measure during the Pressure Loss test. The Volume is specified as part of a
Pressure Loss Test parameter set.
The Leak Rate according to ASTM F2095 is calculated as follows:
P(atm) V (cm 3 )
Q( sccs) =
t ( s)
The parameters and units are:
Q Volume flow cc/s o. sccs

P Pressure loss in the package Atm
V Package volume + System volume cm
t Test Time Seconds
Table 11-1: Parameters for the Leak rate calculation (ASTM)
(1 atm = 1013.25 millibar)
To give an example: A package with a Volume of one liter (1000 cm) is tested for 30 seconds and is losing
10 mbar (= 9.87E-03 atm) in that time. A leak rate of 0.329 sccs is calculated:
9.87e 03 (atm) 1000(cm 3 )

Q( sccs) = = 3.29e -01 [ sccs]
30( s)
To convert the leak rate from sccs to mbar*cm / s, please multiply by 1.01325
This leak rate is used to calculate the theoretical hole size as described on page 11-2 of this chapter.

Hole Size Calculation using Hagen-Poiseullies Law

To calculate a Hole Size using Hagen-Poiseullies Law a Leak Rate (Volume Flow), Path Length (Hole
Length), Differential Pressure and Viscosity are required. The Leak Rate is derived as previously described
on page 11-1. The Differential Pressure is measured during the Pressure Loss test as previously described.
The Hole Length is specified as part of the Pressure Loss Test parameter set. The Viscosity is a constant;
Air is assumed to be the working fluid.
The effective (aggregate) Hole Size is derived using Hagen-Poiseuilles law as follows:
r 4 ( P1 P2 )
Q=
8nl ( l >>r / tube)
Q Volume flow cc/sec

L Hole length cm
R Hole radius cm
P1-P2 Differential pressure Pa
N Dynamic Viscosity Pas [Air = 1.827 x 10-4 at 18C]
Table 11-1: Parameters Hagen-Poiseuille
The pressure in the package is changing during the test, so we set the differential pressure to P1-P2 and:
P
P1 P2 = ( P )
2
This results in:
Q 8 n l
r=
P
(P
4
)
2
The diameter of the hole reduces to:
m Q 8 n l
d = 2 1000
cm 4 ( P P )
2

Manual Lippke4500

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Package Test System 4500

7500 Boone Avenue North

Part Number 143-153

Chapter 2 : Introduction .................................................................................................................................................2-1

Chapter 3 : System Controls & Components.................................................................................................................3-1

Chapter 4 : Installation and Set Up................................................................................................................................4-1

Chapter 5 : Menu Structure............................................................................................................................................5-1

Chapter 7 : Troubleshooting ..........................................................................................................................................7-1

Chapter 8 : Technical Data ............................................................................................................................................8-1

Chapter 9 : Spare parts..................................................................................................................................................9-1

Chapter 10 : Warranty and Service Policies ................................................................................................................10-1

Chapter 11 : Leak Rate and Hole Size Calculation .....................................................................................................11-1

MOCON, Inc. Revision C iii

MOCON, Inc. Revision C iv

Chapter 1: Safety Information

The following symbols are used in order to obtain more clarity:

Caution: Please observe all instructions.

Note, which is helpful in operating and using the test system.

MOCON, Inc. Revision C 1-1

- The system must only be operated by qualified personnel

- It is not allowed to modify, reconstruct or remodel the system improperly

- Safety notices must be observed

It is self-evident that the following regulations apply as well:

- all relevant rules for prevention of accidents

- generally accepted safety regulations

- regulations specific to countries and states

Assembly, installation and commissioning

Use for the intended purpose and application

It is not permitted to continue operation if malfunctions or trouble occur on the system.

Who is allowed to operate the system?

MOCON, Inc. Revision C 1-2

Reconstructions and modifications

Limits of the obligation to instructions and training

MOCON, Inc. Revision C 1-3

How to switch on and off the system safely

Only switch on - if no persons will be endangered

In case of interlinked plants - observe warning signals

- exclude mutual endangering

In case of malfunctions - switch off the system

- inform foreman (superiors)

Before maintenance - set up and observe safety measures

- switch off power supply

- secure against unauthorized restart

- observe instructions in user manual

First think - then take action!

MOCON, Inc. Revision C 1-4

The following Standard tests can be performed:

Burst/Seal Strength Test

MOCON, Inc. Revision C 2-1

The test is divided in 2 phases.

Phase 1: Increasing the package to the pre-filling limit.

The Burst Pressure if the package bursts

MOCON, Inc. Revision C 2-2

Pressure Loss Test

The test is divided into in 3 Phases

Phase 1: The internal pressure is increased to the test level

Figure 2-2: The Pressure Loss test

The results are:

The pressure decrease during the test time

MOCON, Inc. Revision C 2-3

The test is performed in 2 phases:

Phase 1: The pressure in the package is increased to the test level.

The test result is Pass or Fail

Figure 2-3: The Creep Test